So I spent 5 hours last (8:30-1:30pm) working on my jeep, i am putting the 4.0/auto from a 90 XJ into a 95 YJ 2.5/5sp this should be easy, same manufacturer etc... seems that at some point the wiring went to a power distribution system (?) so i have put the complete wiring harness from the XJ into my jeep, the tail light plugs dont match 5 or 6 wires compared to 3, the fuel pump wiring comes from a different feed so i have to combine the harness, the wiper and heater motor are different plugs and amounts of wires.
i guess i was "lucky" that the steering column plugs were the same. i even had to switch the bolts that hold the bulkhead fitting to the firewall. so i have all these extra plugs in my jeep now powerwindows,locks,mirrors,antanea,power seats and speakers wire plugs galore. i was actually able to hook up all the engine plugs,comp.and tcu plugs without to much trouble only to find out that now i have to install the headlight harness from the XJ also! this does not even include mounting the coil pack,the relay deal and reroute the whole harness under the hood. After all this wiring there is still suspension,brakes and body work to do, if i could rewind 6months of my life i would have just bought a stinking 4cyl and shoved it in there and been on the trail allready.i am sure it will all be worth it when i am done 5 years from now.
my luck it will probably go up in flames when i first hit the key, i will have full coverage on it for that event.

unfortunatly the XJ did not have the PDC and all the wires run into the dash wiring, thats why i swapped all of it, the trans and tcase are allready set when i put the XJ rear axle under it (spring over) i should be all right, the driveshaft is at full stuff right now, if i have to go to a sye kit and custom shaft i will. i located the engine trans tc and motormounts with the shaft connected to the rear axle,the front shaft was fine at this time. the fan is going to be a push electric thru the rad. let me know if i am lost on this set-up, i read a few articles on this swap and hope that i am ok.
thanks again

So I spent 5 hours last (8:30-1:30pm) working on my jeep, i am putting the 4.0/auto from a 90 XJ into a 95 YJ 2.5/5sp this should be easy, same manufacturer etc... seems that at some point the wiring went to a power distribution system (?) so i have put the complete wiring harness from the XJ into my jeep, the tail light plugs dont match 5 or 6 wires compared to 3, the fuel pump wiring comes from a different feed so i have to combine the harness, the wiper and heater motor are different plugs and amounts of wires.
i guess i was "lucky" that the steering column plugs were the same. i even had to switch the bolts that hold the bulkhead fitting to the firewall. so i have all these extra plugs in my jeep now powerwindows,locks,mirrors,antanea,power seats and speakers wire plugs galore. i was actually able to hook up all the engine plugs,comp.and tcu plugs without to much trouble only to find out that now i have to install the headlight harness from the XJ also! this does not even include mounting the coil pack,the relay deal and reroute the whole harness under the hood. After all this wiring there is still suspension,brakes and body work to do, if i could rewind 6months of my life i would have just bought a stinking 4cyl and shoved it in there and been on the trail allready.i am sure it will all be worth it when i am done 5 years from now.
my luck it will probably go up in flames when i first hit the key, i will have full coverage on it for that event.

you are almost always money and time ahead to just sell the 2.5L pig and buy a 4.0l beast instead of swapping.

i all ready thought that, i have parts from many other letter vehicles going on this so why not a CJ front clip.
YJ tub
XJ drive train
TJ gas filler neck
ZJ rear disc brakes

and yes the 2.5 went bad, 225000 miles hard miles, the YJ would roll in gear down a small slope, the fan flew off and took out the rad. and then the rear leaf spring snapped in half. i was still driving 100 miles a day as it was.

I see why a build thread is so important, I laffed hard when I read my frustration! I just had a nice trouble free summer of playing with this same jeep, the swap got done (I got a 93xj wire harness, plug and play) front drive shaft was 1" short (kudo's to poster) I did the Hack -n- Tap w/ XJ front drive shaft for the rear. I did SOA on the rear with the factory YJ springs, kept the RC 3 1/2 front SUA. Got rid of sway bars, XJ shifter with TJ console. I home fabbed my sport cage (professionally welded at work) did my rock sliders, D44a rear disc brake swap (stops awesome with 35" mtrs).
I also welded front and rear spiders and added a DIY posilock for the CAD.
So as it sits i am a 95 YJ with approx 5" lift on 35" MTR's 4:10 welded Dana 30/35 combo.
This winter I am planning the Belly Up skid plate and some more armor.
Thanks to all for the support and comments!
PS it took 3 years but the cost was less than $500 total because of trading and selling and buying, would I do it again NO! lol easy to say now, and I have been thinking about selling it to upgrade to a LJ/JK.

I put a 95 Grand Cherokee 4.0 into my 99 TJ that had a 4.0. By the time the motor swap was done, I had to put every single accessory from the original TJ motor on the GC motor (including valve covers, thermostat housing, oil filter) to make it work. Not a single plug, hose, mount, anything would work. CraZy. Never again....